An apparatus and method for roll packing a variety of compressible materials including a radially collapsible mandrel for easy removal of the roll packed material without tearing or telescoping of the material. The apparatus further includes an adjustable compression roller for setting the amount of compression in the rolled material and a roll handling device that facilitates removal of finished rolls from the apparatus. In one embodiment of the invention, a packing material dispenser supplies packing material to the in-fed compressible material as it is wound upon the mandrel.
|
16. An apparatus for roll packing compressible mattress material, the apparatus comprising:
an elongated, radially collapsible mandrel supported by at least one support bearing, the mandrel having a rotational axis along its length, whereby mattress material may be wound upon the mandrel by rotating the mandrel, wherein the outer surface is adjustable to increase or decrease an outer diameter of the mandrel; means for adjusting the amount of compression of the compressible mattress material as it is being wound upon the mandrel; means for directing compressible mattress material between the mandrel and the compressing means so that the compressed mattress material may be wound upon the mandrel; means for dispensing and applying packing material to successive layers of the compressible mattress material as it is wound upon the mandrel; and means for removing the roll of compressible mattress material from the collapsed mandrel.
17. An apparatus for roll packing a compressible material in a roll packing machine having a radially collapsible mandrel, a compression roller proximate the mandrel and adjustable to vary the spacing therebetween, and a packing material dispenser, the apparatus comprising:
means for providing the mandrel in a non-collapsed position supported by at least one support bearing; means for adjusting the spacing between the compression roller and the mandrel to obtain a desired compression of the compressible material; means for directing compressible material between the mandrel and the compression roller such that compressible material can be wound upon the mandrel by rotating the mandrel; means for rotating the mandrel to wind the compressible material onto the mandrel; means for applying packing material to the compressible material as it is wound upon the mandrel; means for stopping rotation of the mandrel when a desired quantity of compressible material has been wound onto the mandrel; means for collapsing the mandrel to release the roll from the mandrel; and means for removing the roll of compressible material from the mandrel.
14. A method of roll packing a compressible material in a roll packing machine having a radially collapsible mandrel, a compression roller proximate the mandrel and adjustable to vary the spacing therebetween, a stripper bar, a roll handler proximate the mandrel, and a packing material dispenser, the method comprising the steps of:
providing the mandrel in a non-collapsed position; adjusting the spacing between the compression roller and the mandrel to obtain a desired compression of the compressible material; winding packing material from the packing material dispenser onto the mandrel; directing compressible material between the mandrel and the compression roller such that compressible material can be wound upon the mandrel by rotating the mandrel; rotating the mandrel to wind the compressible material onto the mandrel; applying packing material to the compressible material as it is wound upon the mandrel; stopping rotation of the mandrel when a desired quantity of compressible material has been wound onto the mandrel; collapsing the mandrel; positioning the roller handler at an end of the mandrel: pushing the finished roll off of the mandrel and into the roll handler using the stripper bar.
1. An apparatus for roll packing compressible material, comprising:
an elongated, radially collapsible mandrel, the mandrel having a rotational axis along its length, whereby material may be wound upon the mandrel by rotating the mandrel, the mandrel having an adjustable diameter; a compression roller operatively associated with said mandrel and having a rotational axis substantially parallel to the rotational axis of the mandrel, the compression roller being adjustable to vary its spacing relative to the mandrel, whereby in-fed material may be compressed between the compression roller and the mandrel as it is being wound upon the mandrel; a drive mechanism operatively connected to a first end of the mandrel to turn the mandrel about its rotational axis; a packing material dispenser proximate the mandrel for receiving and dispensing packing material to the compressible material as it is being wound upon the mandrel; a support bearing located at a second end of the mandrel, opposite the first end, the support bearing being moveable to expose the second end of the mandrel to allow removal of a roll of material from the mandrel; and a stripper bar proximate the mandrel and configured to engage a roll of material on the mandrel and push the material toward the second end and off of the mandrel.
8. An apparatus for roll packing compressible material, comprising:
an elongated, radially adjustable mandrel having a rotational axis along its length, the mandrel including a shaft, a plurality of elongated, overlapping plates movably connected to the shaft and radially disposed about the shaft to form a substantially tubular surface, and a cam fixed to the shaft and configured to move the plates toward or away from the shaft along paths extending radially from the shaft; a compression roller operatively associated with said mandrel and having a rotational axis substantially parallel to the rotational axis of the mandrel, the compression roller being adjustable to vary its spacing relative to the mandrel, whereby in-fed material may be compressed between the compression roller and the mandrel as it is being wound upon the mandrel; a drive mechanism operatively connected to a first end of the mandrel to turn the mandrel about its rotational axis; a packing material dispenser proximate the mandrel for receiving and dispensing packing material to the compressible material as it is being wound upon the mandrel; a feed table upstream of the mandrel for supporting the compressible material and directing the compressible material between the mandrel and compression roller; a support bearing located at a second end of the mandrel, opposite the first end, the support bearing moveable to expose the second end of the mandrel to allow removal of a roll of material from the mandrel; a stripper bar proximate the mandrel and configured to engage a roll of material on the mandrel and push the material toward the second end and off of the mandrel; and a roll handler proximate the second end of the mandrel and configured to receive a roll of material from the mandrel and reposition the roll relative to the apparatus for subsequent processing.
2. The apparatus of
3. The apparatus of
4. The apparatus of
5. The apparatus of
6. The apparatus of
7. The apparatus of
9. The apparatus of
10. The apparatus of
11. The apparatus of
12. The apparatus of
13. The apparatus of
15. The method of
18. The apparatus of
|
This invention relates to the packaging of compressible materials such as foam and spring assemblies used in the manufacture of mattresses and the like, and is more particularly directed to an apparatus for packaging such compressible materials into a roll.
Conventional packaging and transportation of compressible materials such as finished mattresses, as well as foam or spring assemblies used in the manufacture of mattress products, generally involves handling of the materials in an uncompressed state. As such, the shipping and storage of the materials requires much more space than would be required if the materials were provided in a compressed state. To improve the efficiency of shipping and storage, foam mattress cores have been packaged in a compressed state by flattening the foam and sealing it in an evacuated bag. See, for example, U.S. Pat. No. 4,711,067 to Magni. This method of packaging foam cores, however, is not useful in packaging spring assemblies. In addition, storage and transportation efficiencies of the foam could be further improved by packaging the flattened cores into a tight roll.
Roll packing generally involves winding-up a desired material to form a roll and then securing the roll to prevent uncoiling of the roll during handling. In the case of compressible materials such as mattresses and foam or spring cores, it is often desired to compress the materials during the roll packing process to obtain a more dense and compact roll. Various devices have been used to achieve compression of roll packed materials. U.S. Pat. No. 3,927,504 to Forrister discloses an apparatus for rolling resilient foamed sheet material without the use of a mandrel. This machine is not useful for packaging spring assemblies and does not have the capability to package multiple units of a compressible material into a large roll. The device further does not provide for packaging a compressible material with a barrier layer between successive turns of the roll, which barrier layer is desirable to prevent adhesion between successive layers of foam.
Some roll packing systems further include a mandrel for facilitating the winding of the material. For example, U.S. Pat. No. 2,114,008 to Wunderlich discloses a spring packing machine having a radially collapsible arbor for use in roll packing spring assemblies. A barrier layer between successive turns of the roll keeps the spring assemblies separate and permits easy removal of a single assembly from the roll. However, this machine is not useful for roll packing foam material due to the presence of a pressure bar 50, between belt 15 and the collapsible arbor, which would tend to snag a compressed foam as it passed beneath. The disclosed machine also has other drawbacks. For example, to remove a finished roll, the arbor must be removed from the machine and collars must be adjusted to collapse the arbor so that the roll can be taken off the arbor. The arbor must then be replaced in the machine before another roll can be formed. Operation of the machine is thus very labor intensive and ergonomically inefficient.
There is thus a need for a simple apparatus capable of roll packing multiple units of various compressible materials, such as foam mattress cores, mattress spring assemblies, and finished mattress products and which is ergonomically efficient and is capable of providing a barrier layer between successive turns of a formed roll.
The present invention provides a simple machine for roll packing a variety of compressible materials such as foam cores, spring assemblies, and fiber materials used in the manufacture of mattress products, as well as finished mattresses themselves. The machine has a radially collapsible mandrel that permits finished roll packed materials to be easily removed from the machine by sliding the roll off of the mandrel. This radially collapsible mandrel permits rolled materials to be removed without any telescoping or tearing of the materials which is usually caused by binding of the roll packed material on the mandrel. The machine of the present invention is especially useful in roll packing foam materials which are highly susceptible to binding against a mandrel. The simplicity of design of the machine of the present invention further permits use in roll packing practically any compressible material, even materials as diverse as coiled spring assemblies for mattresses and foam cores.
In accordance with the present invention, an apparatus is provided having a radially collapsible mandrel for winding compressible materials to be roll packed. A feed table is provided upstream of the mandrel to support and direct the compressible material to the mandrel. A packing material dispenser is further provided proximate the mandrel to feed packing material to the mandrel with the compressible material. A compression roller associated with the mandrel is used to compress in-fed compressible materials between the compression roller and the mandrel as the material is being wound upon the mandrel. The compression roller is adjustable to vary the spacing between the mandrel and the compression roller so that the amount of compression for the in-fed materials can be varied accordingly. In one exemplary embodiment, a pneumatic cylinder is used to adjust the position of the compression roller relative to the mandrel. The mandrel is driven at one end by a driving mechanism including, for example, a motor and a gearbox, and has a bearing plate at the opposite end. The bearing plate is movable away from the end of the mandrel so that a finished roll of material can be easily pushed off of the mandrel after it has been collapsed. In another exemplary embodiment, the apparatus includes a stripper bar associated with the mandrel to facilitate the removal of finished rolls from the mandrel, and further includes a roll handler for receiving the finished roll as it is pushed off the mandrel.
In further accordance with the present invention, a method for roll packing various compressible materials includes the steps of providing a collapsible mandrel and a compression roller, directing in-fed compressible materials between the mandrel and compression roller, adjusting the spacing between the mandrel and compression roller, winding the compressible material around the mandrel, stopping the mandrel when a desired amount of in-fed material has been wound upon the mandrel, collapsing the mandrel, and removing the roll packed material from the mandrel. A method for roll packing foam materials, in particular, in accordance with the present invention is disclosed in U.S. patent application Ser. No. 09/986,227, entitled "Method for Roll Packing Foam Cores," filed on even date herewith, assigned to the assignee of this application, and incorporated by reference herein in its entirety.
Accordingly, the invention provides a simple apparatus and method for roll packing a variety of compressible materials and which has a collapsible mandrel that facilitates the easy removal of finished rolls without tearing, telescoping, or otherwise damaging the roll packed material. These and other objects and advantages of the present invention shall be made apparent from the accompanying drawings and description.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
An apparatus and method are provided for roll packing compressible materials in a simple and efficient manner without damaging the materials, and wherein the materials can be stored and shipped in a compact state. The present invention may be described and understood by a description of an exemplary apparatus.
With reference to
The apparatus 10 further includes a packing material dispenser 36 which supplies packing material 38, such as paper, plastic or fiber material, to a surface 40 of the in-fed compressible materials 14 as they are fed through the mandrel 12 and compression roller 24. The packing material is then wound with the compressed in-fed material to create a barrier layer between successive turns of the rolled material. In this manner, the barrier layer protects successive layers of in-fed material such as foam and prevents adhesion of the successive layers. The packing material dispenser 36 may further include a guide roller 42, pinch rollers 44, 46, and a tension roller 48 to aid in directing packing material 38 to the in-fed compressible material 14 and also to maintain proper tension and alignment of the packing material 38.
A bearing plate 50 is located at a second end 52 of the mandrel shaft 16, opposite the drive motor 20, and is movable to expose an end of the mandrel 12 so that a finished roll of material 54 may be removed from the mandrel 12. The invention further includes a roll handler 58 for facilitating easy removal of the finished rolls 54. In the exemplary embodiment of
As depicted more fully in
Referring to
While the present invention has been illustrated by the description of an embodiment thereof, and while the embodiment has been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of applicant's general inventive concept.
Patent | Priority | Assignee | Title |
11136154, | Sep 22 2017 | Atlanta Attachment Company | Packaging machine for bedding products |
11905059, | Sep 22 2017 | Atlanta Attachment Company | Packaging machine for bedding products |
7017854, | Apr 21 2003 | L&P Property Management Company | Roll packed compressible materials |
7383676, | Mar 10 2005 | Atlanta Attachment Company | Packaging machine for bedding products |
7458193, | Oct 13 2006 | Primo International | Method and system for preparing mattresses for shipment |
7895813, | Oct 13 2006 | Primo International | Method for preparing mattresses for shipment |
8381647, | Jul 20 2001 | PrintGuard, Inc. | Anti-marking coverings for printing presses |
9868277, | Jul 20 2001 | PrintGuard, Inc. | Anti-marking coverings for printing presses |
9884694, | Sep 19 2012 | MAT PROCESSING, LLC | Rear discharge mat rolling machine with wrapper |
Patent | Priority | Assignee | Title |
1144697, | |||
2114008, | |||
2311383, | |||
3122089, | |||
3129658, | |||
3270976, | |||
3521424, | |||
3927504, | |||
3964232, | Nov 30 1971 | Johns-Manville Corporation | Method of packaging fibrous mat structure |
4109443, | Jan 29 1976 | FOAMEX L P , A DE LIMITED PARTNERSHIP | Method and apparatus for forming convolute foam package |
4377262, | Mar 09 1981 | Windings, Inc. | Two-way collapsible mandrel with winding compression |
4385478, | Nov 06 1980 | HOSIERY CORPORATION OF AMERICA,INC | Folding and packing machine for pantyhose |
4507947, | Aug 04 1982 | CARD-O-MATIC PTY LIMITED, A COMPANY INCORPORATED OF NEW SOUTH WALES | Punch and winding machine |
4532750, | Sep 18 1981 | Ferag AG | Winding body for winding-up continuously arriving flat structures, especially printed products in an imbricated product formation |
4550550, | Mar 31 1983 | CertainTeed Corporation | Automated mineral wool roll-unit processing system |
4711067, | Feb 03 1984 | Giuliano, Magni; Dino-Franco, Magni | Method of packaging a single mattress to a small size to be conveniently carried |
4775111, | Apr 30 1986 | Ferag AG | Method and apparatus for processing flat products, especially printed products |
4967536, | May 02 1986 | Ferrag AG | Apparatus for fabrication of portable tubular-shaped packages formed of printed products, such as newspapers, periodicals and the like |
5101610, | Aug 28 1990 | Ferag AG | Method of processing printing products arriving in an imbricated formation |
5121584, | Nov 02 1989 | Nokia-Maillefer Holding SA | Process and machine for forming a coil of material |
5495700, | Apr 01 1993 | Ferag AG | Process and apparatus for processing printing products |
5765343, | Oct 20 1995 | Individual dental floss packaging method and apparatus | |
5934041, | Jul 23 1996 | Fillmatic Polsterindustrie Maschinen GmbH | Apparatus for packaging of mattresses |
5934046, | Oct 20 1995 | Individual dental floss package forming method and apparatus | |
6098378, | Oct 08 1997 | Method of packaging a single mattress to a small size to be conveniently carried | |
6260782, | Jan 24 1996 | Key Safety Systems, Inc | Retractor spool |
6357209, | Sep 15 1999 | L&P Property Management Company | Method of packaging springs |
6467239, | Sep 15 1999 | L&P Property Management Company | Method of packaging spring units |
Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
Oct 10 2001 | GECIC, JOSIP | L&P Property Management Company | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 012560 | /0033 | |
Oct 22 2001 | L&P Property Management Company | (assignment on the face of the patent) | / |
Date | Maintenance Fee Events |
Apr 06 2007 | M1551: Payment of Maintenance Fee, 4th Year, Large Entity. |
Mar 23 2011 | ASPN: Payor Number Assigned. |
Mar 23 2011 | RMPN: Payer Number De-assigned. |
Apr 07 2011 | M1552: Payment of Maintenance Fee, 8th Year, Large Entity. |
Apr 22 2015 | M1553: Payment of Maintenance Fee, 12th Year, Large Entity. |
Date | Maintenance Schedule |
Nov 04 2006 | 4 years fee payment window open |
May 04 2007 | 6 months grace period start (w surcharge) |
Nov 04 2007 | patent expiry (for year 4) |
Nov 04 2009 | 2 years to revive unintentionally abandoned end. (for year 4) |
Nov 04 2010 | 8 years fee payment window open |
May 04 2011 | 6 months grace period start (w surcharge) |
Nov 04 2011 | patent expiry (for year 8) |
Nov 04 2013 | 2 years to revive unintentionally abandoned end. (for year 8) |
Nov 04 2014 | 12 years fee payment window open |
May 04 2015 | 6 months grace period start (w surcharge) |
Nov 04 2015 | patent expiry (for year 12) |
Nov 04 2017 | 2 years to revive unintentionally abandoned end. (for year 12) |